TRAXX DBM200-3 User manual

Unit 4/1 Rocklea Drive
Port Melbourne Vic 3207
1300 109 108
www.traxxcp.com.au
DBM200-3
DIAMOND CORE DRILLING MACHINES
OPERATING MANUAL
CAUTION:
Machine equipped with overheat thermal protection. When the thermal protection kicks in, always
remove from the work piece and run at no load for at least 3 minutes to allow motor to cool before
returning to operation.

2
Side Handle Lock Screw
Trigger Switch
Lock Button
Main Handle
Gear Selector
Tubular Spirit Level
Model D-Handle Model Pistol-Handle Model
Power Input 110-120V: 1700W, 220-240V: 2000W
Voltage See machine nameplate
No Load min
-1
930 / 1520 / 4270
Capacity (Hand-Held) 80mm (3")
Arbor Thread 1-1/4"UNC & 1/2" BSP
Neck Diameter 60mm
Dimensions 528mm X 106mm X 145mm 437mm X 115mm X 289mm
Net Weight 6.4kg (14 Lbs.)
Indicator Light
Bull's Eye Level
Port
Water Feed Valve
Coupling
Water Feed
Adaptor Head
Vacuum
Adaptor Head
Convertible Models:
Water Feed Valve
Quick-Release Water Coupling
D-Handle Model
Spindle 1-1/4"UNC &,
1/2"BSP
Side Handle Assy.
Indicator Light
Bull's Eye Level
Trigger Switch
Tubular Spirit Level
Main Handle
Gear Selector
Lock Button
Pistol-Handle Model
3
GENERAL SAFETY INSTRUCTIONS
WARNING Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term "power tool" in the warnings refers to your mains-operated (corded) power tool.
1) Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c. Keep children and bystanders away while operating a power tool. Distractions can cause you to
lose control.
2) Electrical safety
a. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
b. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c. Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e. When operating a power tool outdoors, use an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces the risk of electric shock.
f. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk of electric shock.
3) Personal safety
a. Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol
or medication. A moment of inattention while operating power tools may result in serious
personal injury.
b. Use personal protective equipment. Always wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting
to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with
your finger on the switch or energising power tools that have the switch on invites accidents.
d. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may result in personal injury.
e. Do not overreach. Keep proper footing and balance at all times. This enables better control of
the power tool in unexpected situations.
f. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves

3
GENERAL SAFETY INSTRUCTIONS
WARNING Read all safety warnings and all instructions. Failure to follow the warnings and
instructions may result in electric shock, fire and/or serious injury.
Save all warnings and instructions for future reference.
The term "power tool" in the warnings refers to your mains-operated (corded) power tool.
1) Work area safety
a. Keep work area clean and well lit. Cluttered or dark areas invite accidents.
b. Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
c. Keep children and bystanders away while operating a power tool. Distractions can cause you to
lose control.
2) Electrical safety
a. Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any
adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will
reduce risk of electric shock.
b. Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and
refrigerators. There is an increased risk of electric shock if your body is earthed or grounded.
c. Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
d. Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords
increase the risk of electric shock.
e. When operating a power tool outdoors, use an extension cord suitable for outdoor use.
Use of a cord suitable for outdoor use reduces the risk of electric shock.
f. If operating a power tool in a damp location is unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk of electric shock.
3) Personal safety
a. Stay alert, watch what you are doing and use common sense when operating a power
tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol
or medication. A moment of inattention while operating power tools may result in serious
personal injury.
b. Use personal protective equipment. Always wear eye protection. Protective equipment
such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate
conditions will reduce personal injuries.
c. Prevent unintentional starting. Ensure the switch is in the off-position before connecting
to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with
your finger on the switch or energising power tools that have the switch on invites accidents.
d. Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may result in personal injury.
e. Do not overreach. Keep proper footing and balance at all times. This enables better control of
the power tool in unexpected situations.
f. Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves

4
away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts.
g. If devices are provided for the connection of dust extraction and collection facilities,
ensure these are connected and properly used. Use of dust collection can reduce dust-related
hazards.
4) Power tool use and care
a. Do not force the power tool. Use the correct power tool for your application. The correct power
tool will do the job better and safer at the rate for which it was designed.
b. Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot
be controlled with the switch is dangerous and must be repaired.
c. Disconnect the plug from the power source and/or the battery pack from the power
tool before making any adjustments, changing accessories, or storing power tools. Such
preventive safety measures reduce the risk of starting the power tool accidentally.
d. Store idle power tools out of the reach of children and do not allow persons unfamiliar
with the power tool or these instructions to operate the power tool. Power tools are
dangerous in the hands of untrained users.
e. Maintain power tools. Check for misalignment or binding of moving parts, breakage of
parts and any other condition that may affect the power tool’s operation. If damaged,
have the power tool repaired before use. Many accidents are caused by poorly maintained
power tools.
f. Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting
edges are less likely to bind and are easier to control.
g. Use the power tool, accessories and tool bits etc. in accordance with these instructions,
taking into account the working conditions and the work to be performed. Use of the
power tool for operations different from those intended could result in a hazardous situation.
5) Service
Have your power tool serviced by a qualified repair person using only identical replacement
parts. This will ensure that the safety of the power tool is maintained.
Symbols used in this manual
V…….......volts
A…….......amperes
Hz……......hertz
W……......watt
~………....alternating current
n
0
………..no load speed
min
-1
….....revolutions or reciprocation
per minute
......warning of general danger
.….class II tool
.…with electrical earth
.......read these instructions
......always wear eye protection
......always wear a dust mask.
.....always wear hearing protection
.....wear safety-approved hard hat
do not dispose of electric tools,
accessories and packaging together
with household waste material

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DRILL SAFETY WARNINGS
• Wear ear protectors when impact drilling. Exposure to noise can cause hearing loss. NOTE The above
warning applies only to impact drills and may be omitted for drills other than impact drills.
• Use auxiliary handle(s), if supplied with the tool. Loss of control can cause personal injury.
• Hold power tool by insulated gripping surfaces, when performing an operation where the cutting
accessory may contact hidden wiring or its own cord. Cutting accessory contacting a "live" wire may
make exposed metal parts of the power tool "live" and could give the operator an electric shock.
•The locking screw for the ground/earth cable may never be loosened, otherwise there is acute
danger to life!
• Check the ground (earth) connection of the electrical plug.
• Never use the machine without the PRCD fault-current safety switch supplied.
• Always check the PRCD fault-current safety switch for correct functioning before starting a drilling
operation.
• Ensure that no water is allowed to get into the motor unit during operation.
• If you detect a leak in any part of the water supply system, shut the machine down immediately
and repair the fault. Water pressure should not exceed 70 psi (4 bar).
• Take care not to damage gas, water, power and other conduits in the area of the drilling operation.
Drain or shut off these conduits as required.
• Block off the working area and place warning signs on both sides of the wall when drilling through
from one side to the other.
• Take appropriate precautions to ensure that, in the event of a drilling core dropping out, no
personal injury or material damage will result.
• When drilling hollow components, check the flow route of the cooling water in order to prevent
damage.
• Always hold the machine tightly. Diamond core drilling bits can become stuck at any time during core
drilling, there is a danger of the machine jumping out of control.
• WARNING: Pull the plug out of the socket before making device settings or changing accessories.
Many accidents are caused by accidental starting of power tools.
WARNING! 110V UK machines are not equipped with a PRCD portable residual current device or GFCI
ground fault circuit interrupter. The machine must always be used with an isolating transformer for
protection in case an electrical fault should occur.
INTRODUCTION
The machine is equipped with spirit levels which aid in aligning the tool. By positioning the machine so that
the bubble is in the center of the window one can drill a straight hole. Use the Bull's Eye Level for vertical
aligning and the Tubular Level for horizontal aligning.
This machine is for the intended purpose of diamond core drilling of concrete, masonry, stone and similar
materials. The machine may be hand-held for drilling up to 80mm. For sizes above 80mm up to 160mm, it must
be mounted on a rig (drilling stand). The rig is not included.
All other uses which are not for the intended purpose are prohibited.
It is equipped with a water feed system which is required for the diamond core drilling process.
Convertible models also have two adaptor heads: one for water feed and one for through-the-spindle dust
aspiration. It is equipped with a PRCD interrupter (portable residual current device) which must be used at all

6
times. It is equipped with a three speed mechanical gearbox for different core drill size ranges and features a
mechanical safety clutch.
The motor has electronics for soft start, overload protection and thermal (overheating) protection. There is an
indicator light on the machine to alert the operator of load and temperature conditions.
ELECTRICAL CONNECTION
The network voltage must conform to the voltage indicated on the tool name plate.
Under no circumstances should the tool be used when the power supply cable is damaged. A damaged
cable must be replaced immediately by an authorized Customer Service Center. Do not try to repair the
damaged cable yourself. The use of damaged power cables can lead to an electric shock.
WARNING:
This machine is equipped with a Portable Residual Current
Device (PRCD) also known as a Ground Fault Circuit Interrupter
(GFCI). Always use this device whenever using the machine to
reduce the risk of shock hazards. Always position the device
PRCD as close as possible to the power source. Test and reset
the PRCD device before each use. Press the “Test” button to test.
Press the“Reset” button to energize the circuit to the machine.
WARNING!: 110V UK machines are not equipped with a PRCD portable residual current device or GFCI
ground fault circuit interrupter. The machine must always be used with an isolating transformer for
protection in case an electrical fault should occur.
Use an RCD in a separate control box with one or more socket outlets in accordance with EN
60309-2 with the earthing contact position 1 h.
WARNING: Always connect the plug into the wall socket with a drip loop. If the cable leads downward
directly into the wall socket, any water on the cable could run into the socket, causing a hazard.
ASSEMBLY
1. Mount the handle clamp of the side handle onto the gearbox neck. Position the side handle perpendicular
to the main handle. Use the lock screw to tighten the clamp.
2. Thread the water supply assy. Into the hole in the bottom of gearbox and tighten with a wrench.
3. For convertible models: insert either the water feed adaptor head or the vacuum adaptor head into the
port.
LIST OF CONTENTS
• Diamond core drilling machine.
• Side handle assembly
• Water feed assembly
• Wrench
Cover
Test Button Reset Button On Lamp
(Convertible models only:)
• Water feed adaptor head
• Vacuum adaptor head

7
OPERATING INSTRUCTIONS
1) MOUNTING THE CORE BIT
CAUTION: Ensure that the threads of the spindle and the core bit match. Attempting to mount
mismatched threads will result in damage to both threads.
The spindle has two types of threads. The outside male thread is 1-1/4inch UNC, the inside female thread is 1/2
inch BSP.
Ensure both the core bit and the machine spindle are clean. Any debris could cause excessive run-out of the
mounted core bit. Excessive run-out can cause premature failure of the core bit and/or a safety hazard.
Tighten the bit to the spindle using two wrenches. Only use correct sized wrenches to avoid damage to the
spindle or bit.
Choosing the correct core bit for the job:
Ensure that the bit you are using is suitable for the material you are drilling. There are two main types of
diamond core bit:
Wet/dry type-electroplated (surface set) diamond core bits and wet type-sintered (impregnated)
diamond core bits.
We recommend always using wet-type (sintered) bits with this machine.
Electroplated bits, also known as wet/dry type, are only suitable for less hard materials. The diamonds are sharp
and coarse and are only set on the surface. They have a much shorter service life than sintered bits and cannot
be dressed (resharpened). Once they become dull, they must be replaced. They tend to work well with softer,
abrasive materials like brick.
Sintered bits, also known as wet type, are much longer lasting but require operator knowledge for best results.
Water is absolutely always required with sintered bits. The bit is impregnated with many layers of diamond in
its metal matrix. As the matrix (bond) wears, new diamonds are exposed. If the bit becomes glazed, it can be
resharpened by dressing with an appropriate alumina oxide or silicon carbide dressing stick. There are many
variables with sintered diamond core bits, such as diamond grade and type, diamond grit size, bond type,
bond hardness, and bit wall thickness. Consult with your diamond core bit supplier for the best bit for your
application. Work materials vary widely in hardness.
2) WATER SUPPLY
Water is a basic requirement for diamond core drilling. The water serves as a
coolant to avoid the working surface at the tip of the bit from overheating.
When the diamond bit becomes overheated, both the bond matrix and even
the diamonds break down. The most frequent cause of diamond core bit
damage is caused by drilling without enough coolant water.
Water should always be used to cool and lubricate the bit and to flush out
abrasive particles formed while drilling.
Never use this machine without water feed.
Open
Closed
Water Feed Valve

8
To connect the water supply. Attach the quick-release water coupling to a water hose.
WARNING: Never allow water to enter the motor. It could lead to an electric shock.
WARNING: Check all connections of the water feed system to ensure there
are no leaks. Inspect hoses and other critical parts which could deteriorate.
WARNING: The maximum water pressure should not exceed 70 psi (4 bar).
CAUTION: There are two small holes on the top of the gearcase. If either
of these holes leaks water, it indicates that the water seals are worn out.
Replace them immediately.
CAUTION: Never use a wet-only machine without water feed. Running dry will overheat and destroy its
water seals. Only convertible models may be used dry.
Use a water collector with a wet vacuum to collect cooling water if nearby objects could be damaged by water.
WARNING: Never allow water to enter the motor. A perfectly functioning water collector set up must be
used for any drilling performed at an upward angle.
Instructions for Inserting Adaptors for Convertible models:
To attach either the water feed adaptor head or the vacuum adaptor, the universal port on the machine's
gearbox is a bayonet connection. Align the slots on the adaptor with the tangs on the port. Insert fully and
then twist clockwise to tighten.
3) SELECTING SPEEDS
There are 3 speed ranges to suit the bit size and work piece hardness. Choose the
slowest speed for large diameter bits and hard materials. If when cutting the bit
stalls repeatedly, then you must change to a lower gear. If you are already in the
lowest gear and the bit stalls repeatedly, then you are using the machine over its
maximum capacity.
CAUTION: Never attempt to change gears on a running machine! Only adjust when the machine is
at rest.
Select the desired gear range by turning the gear selector either clockwise or counterclockwise into the desired
gear. It will usually be necessary to turn the spindle by hand a little to get it to shift all the way.
Gear Selector
Indicator Holes

9
4) THE SWITCH
The machine has a lockable trigger switch. Squeeze the trigger to start the
machine. To lock the switch on, press the lock button while holding the
trigger switch on. To release, squeeze the trigger and release.
WARNING: Never lock the switch on when drilling hand-held. Only lock the switch on when mounted to
a rig.
5) OVERLOAD PROTECTION, OVERHEAT PROTECTION
Overload Warning System:
When the load reaches overload conditions, the warning system will kick in, lowering the voltage and causing
the motor to stop. Simply back off the downward pressure to ease the load and the motor will automatically
restart.
Then the operator can continue to drill normally.
Overload:
If the excessive load is sustained too long, the motor will shut down
completely and the LED indicator light will glow solid red. In this case, the
motor must be first shut off and then restarted.
When this happens, the motor will very likely be near overheating, so it is
also a good idea to run the motor at no load for a few minutes to cool it
before continuing.
Overheat Thermal Protection:
If the temperature of the motor gets too high, the thermal protection will
shut the motor down and the LED indicator light will glow solid red. The
switch must be first shut off and then restarted. When this happens, do
not immediately start drilling after restarting the motor. Always run the machine at no load for a few minutes
to return to a normal operating temperature before continuing.
CAUTION: The motor will be damaged if it is repeatedly overloaded or overheated. Always cool the
motor .
by running at no load for a few minutes whenever it stops from either overheat or overload.
6) SAFETY CLUTCH
This machine is equipped with a mechanical clutch to protect the operator and machine from excessive torque
forces. When the preset maximum torque level is reached, the clutch will slip. After the clutch slips many times,
it will become worn and slip at lower and lower torque levels. When this happens, it must be serviced by an
authorized service provider. The recommended torque of the clutch nut is 21 Nm.
Trigger Switch
Lock Button
D-Handle Model
Indicator Light
Indicator Light
Pistol-Handle Model

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7) DIAMOND CORE DRILLING
WARNING: When coring through a floor, the core will fall down. Take precautions to avoid injury or
damage below.
NOTE: When drilling with a new bit for the first time, use less than normal feed pressure for a time
until it breaks-in.
1. Press the “Reset” button on the PRCD interrupter device to energize the circuit to the machine. Then
squeeze the trigger switch to turn the machine on.
WARNING: Hold the machine tightly with both hands to counteract the torque reaction force when
the bit begins to turn.
2. Open the water valve slightly and very gently begin the cut. If holding by hand, start the cut by
approaching at an angle of about 30 degrees to the cutting surface. (A large piece of wood with a large V
notch cut in it will help prevent the bit from wandering at the beginning.) Once about a third of the arc is
cut, straighten the bit to the correct perpendicular angle while keeping enough feed pressure on the bit
to prevent it from wandering.
(If using a rig, use very light feed pressure to prevent the bit from wandering until the bit is fully
penetrated into the cut.)
3. Make adjustments to the water feed as needed. The water leaving the cut should be a solid colored
slurry with about the consistency of milk. If the exiting water is clear, then you may reduce the water flow.
If the exiting water is thick and muddy, then increase the water. It’s very important that the water
has enough pressure to flush cutting debris out of the cut.
4. Once in the cut, use steady feed pressure for about 30 seconds, then back off feed pressure for a few
seconds to allow cutting debris to escape the kerf (cutting area) and for the cutting surface of the bit to
cool. This has the added benefit of allowing the motor to remain within a good working temperature.
Repeat this cycle until finished.
5. When the cut is almost finished and the bit is about to break through, the bit will be very liable to get
stuck. Take extra care gripping the machine tightly and reduce feed pressure at this point.
WARNING: Whenever drilling by hand, always hold the drill in a
position so that you can resist the considerable twisting forces
created when the bit grabs. Never operate without the side
handle tightly in place.
WARNING: When the bit grabs, the machine will always twist in
the counterclockwise direction. If you are drilling into the floor,
make sure that the side handle is in front of your left leg, never
between your legs.
WARNING: Always keep your face away from the machine.
Arrange the power supply cable with minimal slack and oriented in such a way that if the machine gets out of
control and spins, it will immediately unplug its own cable.
The diamond impregnated segments in a wet type (sintered) diamond core bit operate on a principle of
Right Wrong

11
controlled erosion. The bond matrix holding the diamonds is continually worn away by abrasion with
the work piece, exposing the harder diamonds to stand proud from the bond matrix. A bit with good
diamond exposure is a sharp bit.
This erosion process causes heat and particles, which require water to cool and rinse free. Without
adequate water, the bit would overheat and be destroyed.
With too much water and not enough feed pressure, there would not be adequate erosion of the bond
matrix (the diamonds not exposed) and the bit becomes dull (diamond segments polish smooth). This
is called glazing and luckily the bit can be de-glazed (sharpened). If the bit seems to refuse to cut anymore,
you know that it is glazed.
See below: ”SHARPENING A GLAZED BIT ”
Never use a sharp motion or the bit will be damaged. Conversely, don’t feed too gently or the diamond
segments will become glazed. Keep the bit steadily working, but don’t be abusive or give the bit shock
impacts into the work surface.
If holding by hand, take great care to keep the bit aligned to the hole. If the bit is crooked, it will easily bind.
If the cut is very deep, the core plug may be obstructing the flow of cooling water. In this case, stop drilling, and
chisel out the core plug before continuing.
CAUTION: If the bit gets stuck, do not try to rock it loose by turning the switch on and off. That is
hazardous and could damage the motor. Rather, unplug the machine and use a wrench on the bit
mounting to work it loose.
If embedded steel such as rebar is encountered take special care. When the steel is encountered, the water
will generally go clear and vibration will begin. Change to a lower gear if available. Reduce the feed pressure
by about 1/3 and let the bit go at its own pace, if there is too much vibration the bit will be destroyed.
Once the steel is passed, continue normally. A properly sharp bit with good diamond exposure should
be able the cut through rebar if handled well.
When the cut is finished keep the motor running until the bit is removed from the cut to avoid it getting
stuck.
CAUTION: Drilling operations are very stressful to the motor and at the end of the cut, the motor
temperature will be very hot, always run the motor at no load for a few minutes until the temperature
returns to a normal range before shutting off. Turn the water feed down to a very small amount of flow
(not off), just enough to keep the water seals from overheating when you perform this step.
Then turn off the switch and allow the coasting bit to stop before setting it down.
RESHARPENING A GLAZED BIT
If the bit becomes glazed, the ideal way to resharpen and true it up is by dressing with an appropriate alumina
oxide or silicon carbide dressing stone. Simply drill into the stick as many times as necessary to restore its
cutting performance.
If it is only slightly dull, while cutting, you may first reduce the water flow by about half until the water exiting
the kerf is really muddy.
Another method is to stop and add about 6mm (1/4”) of coarse silica sand in the kerf and and drill for a few
minutes, then turn up the water to rinse the sand free. Repeat as needed.

12
Another method is to drill into a cinder block. Repeat as needed.
If that still does not work the only choice is to use a dressing stone.
VIBRATION TROUBLESHOOTING
If vibration occurs and it is not caused by embedded steel, stop drilling to find the cause and remedy.
CAUTION: Do not operate with vibration or there will be serious hazard and the diamond core bit
will surely be destroyed.
Vibration is usually caused by:
1. A bit with too much runout
SOLUTION: Replace bit.
2. A bit with diamond segments broken off
SOLUTION: Repair or Replace bit.
KEEP TOOL CLEAN
Wipe down the machine at the end of each work day with a damp cloth.
NEVER use solvents to clean plastic parts. They could possibly dissolve or otherwise damage the material.
Periodically blow low-pressure compressed air through the ventilation slots with the motor running to keep
the motor clean so that motor can be cooled normally.
Wear safety glasses while using compressed air.
CAUTION: When drilling in a position with the motor near to the floor, take measures to prevent dust,
debris and slurry from being sucked into the motor's cooling slots
MAINTENANCE
Every 50 hours of operation blow compressed air through the motor while running at no load to clean out
accumulated dust. (If operating in especially dusty conditions, perform this operation more often.)
To keep your diamond coring machine in top condition, periodic maintenance must be performed. In
addition always check for a damaged power supply cable, check for loose fasteners and always keep alert
for unusual noises and vibration when operating.
WARNING: Never operate a damaged machine. Always tag a damaged machine and take it out of
service until repairs can be made.
CAUTION: This machine is equipped with an oil bath gearbox. To avoid leakage of lubricating oil,
whenever the gearbox is opened, the o-ring seal must be replaced with a new one.
Maintenance which should be performed by an authorized service center, include the following:
• Replace water seals as needed.
• Replace the carbon brushes as needed

13
• Change the gear oil about every 100 hours of operation
• Replace the clutch discs and spring as needed.
Each year perform a full mechanical inspection, cleaning and re-lubrication.
THE CARBON BRUSHES
The carbon brushes are a normal wearing part and must be replaced when they reach their wear limit. This
machine is equipped with auto-stop carbon brushes. If the machine comes to a stop unexpectedly, the brushes
should be checked. The auto-stop brush design protects the motor by stopping the machine before the carbon
brushes are completely worn out.
Caution: Always replace the brushes as a pair.
To replace:
1. Remove the 4 screws and remove the motor tail cover. For D-handle models, the D-handle must first be
removed. Remove the 13 screws to remove the D-handle and tail cover. Carefully move the parts to one
side, taking care not to strain the wiring.
2. Using pliers rotate the brush spring out of the way and slide the old carbon brush out of the brush
holder.
3. Unscrew the screw to remove the brush lead. The old carbon brush may now be lifted away.
4. Install a new brush. Installation is the reverse of removal.
5. Replace the motor tail cover. For D-handle models, replacement of the D-handle is the reverse of removal.
Take care not to pinch any wires when reassembling.
If the replacement of the power supply cord is necessary, this has to be done by the manufacturer or
their agent in order to avoid a safety hazard.
WARNING: All repairs must be entrusted to an authorized service center. Incorrectly performed repairs
could lead to injury or death.
Do not throw electric power tools into the household waste!
In accordance with the European Directive 2002/96/EG on Waste Electrical and Electronic Equipment and
transposition into national law, used electric power tools must be collected separately and recycled in an
environmentally friendly manner.

15
WIRING
LED
1
2
1
2
AC
BRUSH BRUSH
STATOR
BLACK BLACK
BLACK BLACK
BLACK
(TEMP. SENSOR)
ELECTRONICS UNIT
SWITCH
WHITE WHITE

16
D-Handle Model Exploded View
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35 36
25
91
29 28
55
65
38
37
39
40
42
44
45
46
97
14
14
07
13
09
15
15
12
11
74
NO.01~99 V1.9
64
63
85
17
18
19
22
21
26
99
56
60
59
81
84A
86
89
94
39
27
08
93
90
83
82
95
96
84B
OPTIONAL
98
04 05
06
03
01
02

17
D-Handle Model Parts List
NO. Parts Name Q'TY
1 POWER SUPPLY CORD 1
2 PRCD INTERRUPTER PROTECTION(OPTIONAL) 1
3 CORD ARMOR 1
4 CORD CLIP 1
5 SCREW M4 x 14 2
6 BULLS-EYE LEVEL 1
7 SWITCH LOCK-ON 1
8 TUBULAR SPIRIT LEVEL 29 x 10 2
9 LED OVERLOAD LAMP 26cm 1
10 N/A -
11 D-HANDLE HOUSING-RIGHT 1
12 D-HANDLE HOUSING-LEFT 1
13 SCREW M4 x 16 6
14 SOCKET CAP SCREW M5 x 40 4
15 SOCKET CAP SCREW M5 x 16 4
16 N/A -
17 TAIL COVER 1
18 INSULATING COVER 1
19 SCREW M4 x 12 2
20 N/A -
21 BRUSH SPRING 2
22 CARBON BRUSH 7 x 17 x 17 2
23~24 N/A -
25 NUT M5 2
26 INSULATING SLEEVE 2
27 MOTOR HOUSING 1
28 ELECTRONICS UNIT 1
29 SCREW M4 x 10 2
30 MOTOR INSULATION SLEEVE 1
31 STATOR 1
32 SCREW M5 x 95 2
33 BALL BEARING 6200-2R 1
34 ARMATURE M1.0 x 8T 1
35 BALL BEARING 6201ZZ 1
36 OIL SEAL SG Ø12 x Ø22 x 7 1
37 GEAR PLATE 1
38 O-RING Ø2 x Ø92 x Ø96 1
39 BALL BEARING 608 ZZ 2
40 CLUTCH NUT M10 x P1.25 1
41 N/A -
42 PRESSURE DISC 10 x Ø12 x Ø28 x 3 1
43 N/A -
44 INPUT/CLUTCH GEAR M1.0 x 38T 1
45 BUSHING Ø12 x Ø18 x 5.3 1
46 INPUT SHAFT M1.25 x 24T x 12T x 8T 1
47 N/A -
48 NEEDLE BEARING HK1010 1
49 RETAINING RING ISTW 14 1
50 OUTPUT GEAR M1.25 x 29T 1
NO. Parts Name Q'TY
51 SLIDING GEAR M1.25 x 42T 1
52 RETAINING RING ISTW 18 1
53 OUTPUT GEAR M1.25 x 46T 1
54 OIL SEAL Ø22 x Ø32 x 7 1
55 GEAR CASE 1
56 SOCKET CAP SCREW M5 x 12 1
57 N/A -
58 N/A -
59 O-RING Ø3 x Ø20 x Ø26 1
60 GEAR SELECTOR 1
61~62 N/A -
63 WATER FEED CONNECTOR KIT 1
64 WATER COUPLING 1
65 SOCKET CAP SCREW M5 x 50 4
66 WATER SEAL Ø25 x Ø45 x 7 1
67 WATER SEAL Ø25 x Ø47 x 7 1
68 INTERNAL CIRCLIP R-47 1
69 EXTERNAL CIRCLIP S-25 1
70 BALL BEARING 6205-2R 1
71 PARALLEL KEY 5 x 5 x 40 1
72 N/A -
73 N/A -
74 INTERNAL CIRCLIP R-52 1
75 PIN Ø4 x 11.8 2
76 ANTI-SEIZE CUP 1
77 O-RING Ø1.5 x Ø32 x Ø35 2
78 WASHER Ø32 x φ Ø52 x 1 1
79 ANTI-SEIZE RING 1
80 O-RING Ø1.5 x Ø49 x Ø52 1
81 HANDLE CLAMP 1
82 SPACER Ø6.1 x Ø12 x 10 1
83 LOCK SCREW 1
84A FRONT HANDLE 1
84B ANIT-VIBRATION RUBBER HANDLE 1
85 WRENCH M32 1
86 FAN BAFFLE Ø48 x Ø87.5 x 1 1
87~88 N/A -
89 O-RING Ø1.5 x Ø30 1
90 SCREW M4 x 8 1
91 BRUSH HOLDER PLATE ASSY. 1
92 N/A -
93 STAR WASHER M5 1
94 SCREW M4 x 6 2
95 SCLUTCH DISC SET 1
96 GASKET 1
97 SPINDLE SET 1
98 PILOT DRILL SOCKET(OPTIONAL) 1
99 SELECTOR DISC 1

18
Pistol-Handle Model Exploded View
12
11
13
15
15
NO.01~100 V1.7
14
06
16
80
79
78
77
77
75
71
54
53
52
51
50
49
48
27
30
31
32
33
34
35 36
25
29 28
55
65
38
37
39
40
42
44
45
46
98
74
64
63
85
18
19
22
21
26
100
56
60
59
86
70
69
67
66
68
17
89
90
95
39
76
92
93
94
91
81
83
82
96
97
84A
84B
OPTIONAL
99
05 04
09
01
03
02
07

19
Pistol-Handle Model Parts List
NO. Parts Name Q'TY
1 POWER SUPPLY CORD 1
2 PRCD INTERRUPTER PROTECTION(OPTIONAL) 1
3 CORD ARMOR 1
4 CORD CLIP 1
5 SCREW M4 x 14 2
6 BULLS-EYE LEVEL 1
7 SWITCH LOCK-ON 1
8 N/A -
9 LED INDICATOR LIGHT 15cm 1
10 N/A -
11 PISTOL HANDLE HOUSING-RIGHT 1
12 PISTOL HANDLE HOUSING-LEFT 1
13 SCREW M4 x 16 4
14 SOCKET CAP SCREW M5 x 30 4
15 SOCKET CAP SCREW M5 x 20 4
16 BUTT PLATE 1
17 TAIL COVER 1
18 INSULATING COVER 1
19 SCREW M4 x 12 2
20 N/A -
21 BRUSH SPRING 2
22 CARBON BRUSH 7 x 17 x 17 2
23~24 N/A -
25 NUT M5 2
26 INSULATING SLEEVE 2
27 MOTOR HOUSING 1
28 ELECTRONICS UNIT 15cm 1
29 SCREW M4 x 10 2
30 MOTOR INSULATION SLEEVE 1
31 STATOR 1
32 SCREW M5 x 95 2
33 BALL BEARING 6200-2R 1
34 ARMATURE M1.0 x 8T 1
35 BALL BEARING 6201ZZ 1
36 OIL SEAL SGØ12 x Ø22 x 7 1
37 GEAR PLATE 1
38 O-RING Ø2 x Ø92 x Ø96 1
39 BALL BEARING 608 ZZ 2
40 CLUTCH NUT M10 x P1.25 1
41 N/A -
42 PRESSURE DISC 10 x Ø12 x Ø28 x 3 1
43 N/A -
44 INPUT/CLUTCH GEAR M1.0 x 38T 1
45 BUSHING Ø12 x Ø18 x 5.3 1
46 INPUT SHAFT M1.25 x 24T x 12T x 8T 1
47 N/A -
48 NEEDLE BEARING HK1010 1
49 RETAINING RING ISTW 14 1
50 OUTPUT GEAR M1.25 x 29T 1
NO. Parts Name Q'TY
51 SLIDING GEAR M1.25 x 42T 1
52 RETAINING RING ISTW 18 1
53 OUTPUT GEAR M1.25 x 46T 1
54 OIL SEAL Ø22 xØ32 x 7 1
55 GEAR CASE 1
56 SOCKET CAP SCREW M5 x 12 1
57 N/A -
58 N/A -
59 O-RING Ø3 x Ø20 x Ø26 1
60 GEAR SELECTOR 1
61~62 N/A -
63 WATER FEED CONNECTOR KIT 1
64 WATER COUPLING 1
65 SOCKET CAP SCREW M5 x 50 4
66 WATER SEAL Ø25 x Ø45 x 7 1
67 WATER SEAL Ø25 x Ø47 x 7 1
68 INTERNAL CIRCLIP R-47 1
69 EXTERNAL CIRCLIP S-25 1
70 BALL BEARING 6205-2R 1
71 PARALLEL KEY 5 x 5 x 40 1
72 N/A -
73 N/A -
74 INTERNAL CIRCLIP R-52 1
75 PIN Ø4 x 11.8 2
76 ANTI-SEIZE CUP 1
77 O-RING Ø1.5 x Ø32 x Ø35 2
78 WASHER Ø32 x Ø52 x 1 1
79 ANTI-SEIZE RING 1
80 O-RING Ø1.5 x Ø49 x Ø52 1
81 HANDLE CLAMP 1
82 SPACER Ø6.1 x Ø12 x 10 1
83 LOCK SCREW 1
84A FRONT HANDLE 1
84B ANIT-VIBRATION RUBBER HANDLE 1
85 WRENCH M32 1
86 FAN BAFFLE Ø48 x Ø87.5 x 1 1
87~88 N/A -
89 O-RING Ø1.5 x Ø30 1
90 SCREW M4 x 8 1
91 SCREW M4 x 8 1
92 BRUSH HOLDER PLATE ASSY. 1
93 TUBULAR SPIRIT LEVEL 29 x 10 1
94 STAR WASHER M5 1
95 SCREW M4 x 6 2
96 CLUTCH DISC SET 1
97 GASKET 1
98 SPINDLE SET 1
99 PILOTDRILLSOCKET(OPTIONAL 1
100 SELECTOR DISC 1

20
Convertible Models: D-Handle Model Exploded View
80
79
78
77
77
76
75
70
69
67
66
68
71
54
53
52
51
50
49
48
30
31
32
33
34
35 36
25
92
29 28
55A
65
38
37
39 40
42
44
45
46
14
14
07
13
09
15
15
12
11
74
NO.01~111 Version 2.0
85
17
18
19
22
21
26
104
56
60
59
81
86
89
94
39
27
08
93
90
83
82
100
101
84B
OPTIONAL
102
103
04 05
06
03
01
02
111
110 108 109 108 108 107 106 105
98 99 97 96 95
FOR NO.55A FOR NO.55B
55B
84A

21
Convertible Models: D-Handle Model Parts List
NO. Parts Name Q'TY
1 POWER SUPPLY CORD 1
2 PRCD INTERRUPTER PROTECTION(OPTIONAL) 1
3 CORD ARMOR 1
4 CORD CLIP 1
5 SCREW M4 x 14 2
6 BULLS-EYE LEVEL 1
7 SWITCH LOCK-ON 1
8 TUBULAR SPIRIT LEVEL 29 x 10 2
9 LED OVERLOAD LAMP 26cm 1
10 N/A -
11 D-HANDLE HOUSING-RIGHT 1
12 D-HANDLE HOUSING-LEFT 1
13 SCREW M4 x 16 6
14 SOCKET CAP SCREW M5 x 40 4
15 SOCKET CAP SCREW M5 x 16 4
16 N/A -
17 TAIL COVER 1
18 INSULATING COVER 1
19 SCREW M4 x 12 2
20 N/A -
21 BRUSH SPRING 2
22 CARBON BRUSH 7x17x19 2
23~24 N/A -
25 NUT M5 2
26 INSULATING SLEEVE 2
27 MOTOR HOUSING 1
28 ELECTRONICS UNIT 1
29 SCREW M4 x 10 2
30 MOTOR INSULATION SLEEVE 1
31 STATOR 1
32 SCREW M5 x 95 2
33 BALL BEARING 6200-LLU 1
34 ARMATURE M1.0 x 8T 1
35 BALL BEARING 6201ZZ 1
36 OIL SEAL SGØ12 x Ø22 x 7 1
37 GEAR PLATE 1
38 O-RING Ø2 x Ø92 x Ø96 1
39 BALL BEARING 608 ZZ 2
40 CLUTCH NUT M10 x P1.25 1
41 N/A -
42 PRESSURE DISC 10 x Ø12 x Ø28 x 3 1
43 N/A -
44 INPUT/CLUTCH GEAR M1.0 x 38T 1
45 BUSHING Ø12 x Ø18 x 5.3 1
46 INPUT SHAFT M1.25 x 24T x 12T x 8T 1
47 N/A -
48 NEEDLE BEARING HK1010 1
49 RETAINING RING ISTW 14 1
50 OUTPUT GEAR M1.25 x 29T 1
51 SLIDING GEAR M1.25 x 42T 1
52 RETAINING RING ISTW 18 1
53 OUTPUT GEAR M1.25 x 46T 1
54 OIL SEAL Ø22 x Ø32 x 7 1
55A,B GEAR HOUSING 1
NO. Parts Name Q'TY
56 SOCKET CAP SCREW M5 x 12 1
57 N/A -
58 N/A -
59 O-RING Ø3 x Ø20 x Ø26 1
60 GEAR SELECTOR 1
61~64 N/A -
65 SOCKET CAP SCREW M5 x 50 4
66 WATER SEAL Ø25 x Ø45 x 7 1
67 WATER SEAL Ø25 x Ø47 x 7 1
68 INTERNAL CIRCLIP R-47 1
69 EXTERNAL CIRCLIP S-25 1
70 BALL BEARING 6205-LLU 1
71 PARALLEL KEY 5 x 5 x 40 1
72 N/A -
73 N/A -
74 INTERNAL CIRCLIP R-52 1
75 PIN Ø4 x 11.8 2
76 ANTI-SEIZE CUP 1
77 O-RING Ø1.5 x Ø32 x Ø35 2
78 WASHER Ø32 x Ø52 x 1 1
79 ANTI-SEIZE RING 1
80 O-RING Ø1.5 x Ø49 x Ø52 1
81 HANDLE CLAMP 1
82 SPACER Ø6.1 x Ø12 x 10 1
83 LOCK SCREW 1
84A FRONT HANDLE 1
84B ANIT-VIBRATION RUBBER HANDLE 1
85 WRENCH M32 1
86 FAN BAFFLE Ø48 x Ø87.5 x 1 1
87~88 N/A -
89 O-RING Ø1.5 x Ø30 1
90 SCREW M4 x 8 1
91 N/A -
92 BRUSH HOLDER PLATE ASSY. 1
93 STAR WASHER M5 1
94 SCREW M4 x 6 2
95 O-RING Ø22 x 1.5 1
96 UNIVERSAL PORT 1
97 SCREW M4 x 16 4
98 VACUUM ADAPTOR 1
99 WATER FEED CONNECTOR KIT 1
100 GASKET 1
101 CLUTCH DISC SET 1
102 SPINDLE SET 1
103 PILOT DRILL SOCKET(OPTIONAL) 1
104 SELECTOR DISC 1
105 NIPPLE 3/4"PS-14 1
106 SEAL (Ø19xØ26x3) Ø19xØ26xØ3 1
107 GEKA FEMALE CLAW 3/4"BSP 1
108 SEAL Ø36xØ29.5xØ12 3
109 GEKA HOSE CLAW 1-1/2" 1
110 GEKA MALE CLAW 1/4"BSP 1
111 WATER FEED CONNECTOR KIT 1